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I use a fusible batting that you can buy at Wal-Mart. I usually press it to the lining and not the outer fabric. makes it easier to put together without the batting moving around and you can cut the batting withoutseam allowances so it doesn't make the seams bulky.

Jon,
I personally would use a cotton batting. The poly batting will eventually ball up after several washings. I've learned that mistake from years of quilting. If there is nothing to keep the batting from shifting about (ie quilting, like on the sleevecaps) it will tend to look lumpy. I use a 100% cotton batting in mine. Theres my 2 cents. Hope it helps.
Christi

Thanks for the advise ppl. After a little shopping around i am going to try something a little different. I managed to buy some very thin (5mm) flexible foam (similar to the stuff which backs ironing board covers). I am going to glue in between the inner and outer material of the flak vest and see what happens.

either this will give me the look i am after or i will end up a cruppled heap in the corner crying

I will post pics in a couple of days once i am done. Wish me luck, i am going in